Audio Source Switch and Volume Control Boxes

3D Printed Audio Source Switch and Volume Control Boxes

DOWNLOAD Version 1.4 (2022-08-04) ZIP ~16MB

INTRO

Below you will find parts and tools, which will help you to print and assemble audio source switch and volume control boxes. If you noticed mistakes, have questions or suggestions, know better component (available in EU and US), please write or send link to info@jocys.com • Project page: Jocys.com/Switch

Parts were printed from PETG with Prusa3D i3 MK3 Printer . If your printer is not precise enough, printed parts may not fit into each other and may not look good.

If you made your own updates or (file) changes, related to this project, please send me a link. I will add this link to your work on this page.

Why I decided to make my own switch? I tested few audio switches. Ground wires of both audio sources were connected together in all of them. Why? I understand, that manufacturers can save few € by using cheaper switches with fewer poles, but consequences of that are unacceptable. Unnecessary ground merging creates audio noise and anomalies. You need to buy and use ground loop isolators to eliminate this noise, but ground loop isolators degrade quality of the audio slightly. I wanted audio to go through ground loop noise isolators ONLY, when both audio sources are merged (when you want to hear audio from both computers at the same time). To avoid audio merging, while switching sources, I used non-shorting switches. Also, I wanted to switch headphones and stereo microphone with ability to switch off (disconnect) microphone completely. With stereo microphone you can have better environment noise elimination options in software. I didn’t want to use powered audio mixers or interfaces, which needs power and processes (distorts) signal in any way.

Features:

1. Microphone switch: PC1 • OFF • PC2. 2. PC1 audio volume control. 3. PC2 audio volume control. 4. Audio source switch: PC1 • PC2. 5. Audio source merge: PC# (OFF) • PC1 + PC2 (ON) - audio signal grounds of PC1 and PC2 are merged and audio goes through ground loop noise isolators ONLY, when audio signals are merged. This allows to avoid audio quality degradation, when unnecessary and you don't need to listen both computers at the same time.

UPDATES

1.4 (2022-08-04) • 35° angle connector added. 1.3 (2022-08-02) • 35° angle adapters added. 1.2 (2022-07-31) • Large and medium boxes removed. Small box and knobs updated. 1.0 (2020-06-06) • Released 1.1 (2020-06-09) • Smooth shaft button added, knurled removed. Knobs redesigned to hide screw hole and to reduce ZIP from 67 to 11 MB. 0.1 (2020-04-25) • ...

PARTS

PARTS WITHOUT TOOLS AND DELIVERY

TOTAL €120 2022-08-04

Mouser €20 Audio switches, potentiometers for volume control

Farnell €26 3.5mm jacks sockets

Kenable €7 3.5mm cables

Neoteck €28 Ground loop isolators

12voltplanet €8 0.5mm² 11A cables

Affixit €6 Bumper stops

Accu €5 Cup point grub screws and nuts for knobs

Amazon / MCPP BasicFill €20 0.8 kg PETG 3D printer filament

ROTARY SWITCH FOR AUDIO SOURCE SWITCHING

Find on Mouser (EU) • Digi-Key (US)

2 x Taiwan Alpha • SR2511F-0602-19R0B-E9-N-W-159

Rotary switch with 6 poles and 2 positions for "Audio Source Switch" and "Audio Merge Switch" boxes.

I would not recommend to buy cheap Chinese rotary switches. They are, usually, made from softer metal and after several dozen switches lose switching smoothness.

Series: SR2511F Product Category: Rotary Switches Number of Positions: 2 Position Number of Decks: 1 Deck Number of Poles per Deck: 6 Pole Current Rating: 300 mA Voltage Rating AC: 125 VAC Index Angle: 0 deg Contact Style: Non-Shorting ( Non-Shorting / Break-Before-Make ) Termination Style: Solder Lug Thread Size: M9xP0.75 (9mm)

1 x Taiwan Alpha • SR2511F-0403-19R0B-E9-N-W-159

Find on Mouser (EU) • Digi-Key (US)

Rotary switch with 4 poles and 3 positions for "Microphone Switch" box.

I would not recommend to buy cheap Chinese rotary switches. They are, usually, made from softer metals and after several dozen switches lose switching smoothness.

Series: SR2511F Product Category: Rotary Switches Number of Positions: 3 Position Number of Decks: 1 Deck Number of Poles per Deck: 4 Pole Current Rating: 300 mA Voltage Rating AC: 125 VAC Index Angle: 0 deg Contact Style: Non-Shorting ( Non-Shorting / Break-Before-Make ) Termination Style: Solder Lug Thread Size: M9xP0.75 (9mm)

ROTARY POTENTIOMETER FOR VOLUME CONTROL

2 x Bourns • PTD902-1015K-A102

Find on Mouser (EU) • Digi-Key (US)

Sennheiser uses 500Ω potentiometer in HZR 62 volume control for HD 62 TV 32Ω headphones. Creative uses 1000Ω (1KΩ) potentiometer in Volume Control Module for Sound Blaster Zx. 10000Ω (10KΩ) potentiometers are too strong for Sennheiser HD 598 50Ω headphones.

Bourns rotary potentiometer for volume control box.

Series: ProAudio PTD90 (9mm) Resistance: 1 kOhms Taper: Audio Number of Turns: 1 Turn Number of Gangs: 2 Gang Element Type: Carbon Tolerance: 10 % Thread Size: M7xP0.75 (7mm) Shaft Type: Knurled / Serrated Shaft Diameter: 6 mm Shaft Length: 15 mm Termination Style: Through Hole Mounting Style: Panel Mount Life: 15000 Cycles Power Rating: 25 mW Voltage Rating: 20 VDC, 150 VAC

3.5MM 3 POLE JACK SOCKET